Fused Filament Fabrication of Bio-Based Polyether-Block-Amide Polymers (PEBAX) and Their Related Properties

This paper describes the application of poly(ether-block-amide) polymers, so-called Pebax, in fused filament fabrication (FFF). Pebax^® is a thermoplastic elastomer (TPE), a copolymer based on rigid polyamide and soft polyether blocks. By variation of the blocks, unique properties such as soft or rigid behaviour are tailored without additional additives and plasticisers. Pebax^®Rnew^® polyamide blocks are bio-based and made from castor beans that allow the design of sustainable applications. In this study, two types of Pebax were selected, processing parameters were characterised, filaments were extruded and applied to FFF printing, and the final mechanical characteristics were determined. Both types were suitable for FFF processing with improved process stability due to less shear thinning and good mechanical performance. The connection strength between the grades was also described in the design context for complex parts with tailored soft or hard regions. Combining the two materials in one design is a promising concept, and the adhesion strength is close to the strength in the Z-direction of the flexible Pebax^®Rnew^®35R53 grade.